OPERATING INSTRUCTIONS

FlowJam
BULK FLOW DETECTION

ENVEA Process GmbH - Gutedelstraße 31 – 79418 Schliengen - GERMANY

Tel.: +49 (0) 7635 827248-0 / info.process@envea.global / www.envea.global
CONTENTS Page

1. System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Regular use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2 Identification of hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.4 Technical progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4. Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.1 A measuring point consists of the following components . . . . . . . . . . . . . . . . . . . . . 5

4.2 Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.3 Sensor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.4 Installation of the sensor on conveyor belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.1 Electrical connection sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.2 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7. Fault clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8. Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1. System overview
A measuring point consists
of the following components:

• Sensor

• Processadapter (optional)

• G-1½“ sensor mount for welding on the pipe

Fig. 1: Overview FlowJam measuring point

2. Function
The radar flow detector FlowJam indicates the flow of bulk materials which move through the detection
range (fig. 1) at a minimal required speed of 0.1 m/s.
The detection is executed by evaluating the Doppler’s effect, thus independent of the flow direction.
The material flow, which can be in metallic or nonmetallic tubes, wells, free fall distances and discharge
points, is indicated by a relay.
The sensor distinguishes between two conditions:
• material flow
• material jam or standstill.
FlowJam can be adapted to extreme process conditions like high process temperature by a separating flange
equipped with a window especially for microwaves.

Fig. 2: Detection range

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3. Safety
The sensor FlowJam was designed, built and tested to be safe and was shipped in safe condition.
Nevertheless persons or objects may be endangered by components of the system if these are operated in an
inexpert manner. Therefore the operational instructions must be read completely and the safety notes must be
followed.
In case of inexpert or irregular use, the manufacturer will refuse any liability or warranty.

3.1 Regular use

• Only original spare parts and accessories of ENVEA Process must be used.
• The measuring system may only be used for material detection. Other uses and modifications of the
measuring system are not permitted.

3.2 Identification of hazards

• Possible dangers when using the measuring system are highlighted in the operating instructions with
the following symbols:

Warning!
• This symbol is used in the operating manual to denote actions which, if not performed correctly may
result in death or injury.

Attention!
• This symbol is used in the operating manual to denote actions which
may result in danger to property.

3.3 Operational safety

• The sensor must be installed by trained and authorised personnel only.
• Switch off the power supply for all maintenance, cleaning or inspection works on the tubes or on
components of the FlowJam.
• Before hot work the sensor must be removed from the installation place.
• The components and electrical connections must be checked for damages regularly. If a damage is
found, it is to be repaired before further operation of the instrument.

3.4 Technical progress

• The manufacturer reserves the right to adapt technical data to the technical progress without particular
advance notice. If you have any questions, ENVEA Process will be pleased to inform you on possible
changes and extensions of the operating instructions.

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4. Mounting and installation
4.1 A measuring point consists of the following components:

• Sensor

• Processadapter (optional)

• G-1½“ sensor mount for welding on the pipe

• Installation instructions

4.2 Required equipment

• Suitable tool for installing the sensor mount

• Approved tools for electrical connection

4.3 Sensor installation

Proceed as follows to install the sensor:
• The sensor should be installed in a low-vibration environment.
• Make sure that there are no moving parts in the detection area. If this is unavoidable, it is strongly
recommended to shield the moving parts.
• For horizontal or inclined installation situations, installation from above is recommended.
• An installation angle to the flow direction between 45 ° - 90 ° should be maintained.
• When used on delivery lines made of non-conductive material, the measurement is made through the
wall. There is no need for a separate recess in the line. In order to eliminate possible interfering signals
from the environment, ENVEA Process offers individual solutions.
• The measuring point can be installed in the following variants:
- in a G 1½ “ sensor mount (Fig. 3)
- with a flange (Fig. 4)
- mounted by means of a pipe clamp (Fig. 5)
- for high-temperature and high-pressure applications with a separating flange (Fig.6)

Fig. 3: Thread mounting Fig. 4: Flange mounting

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 A

Fig. 5: Mounting with pipe clamp Fig. 6: Mounting with separating flange

4.4 Installation of the sensor on conveyor belts

If possible, the installation on conveyor belts is to be executed in the area of the discharge point.
If FlowJam is installed directly above a conveyor belt or if the bulk material to be detected does not show
much profile, the sensor should be mounted at an angle of approx. 70 - 80° (fig. 7).

Fig. 7: Installation above conveyor belt

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5. Electrical connection
The cable length between power supply and measuring point is a maximum of 200 m. A double insulated
shielded cable with a minimum cross section of 0.75 mm² is recommended. From a cable length of 100 m,
the cable cross-section must be increased to 1 mm².
The sensor has an EMV cable gland, this serves for laying a cable shield. The shield should only be placed on
sensor site.

5.1 Electrical connection sensor

1 Uin +24 V
LED 2
2 Uin 0 V
LED 1
3 Relay contact NC (make contact)
4 Relay contact COM S1 S2
5 Relay contact NO (break contact)
5 4 3 2 1

P1 P2

L H 0.25 s 5 s

Fig. 8: Electrical connection and control elements

5.2 Control elements

Status LED

LED 1 red The flashing frequency of the red LED provides

information about the signal strength:
• Fast flashing = high signal strength
• Slow flashing = low signal strength
• Continous flashing = indication of sensor defect
• LED off = no received signal

LED 2 green The green LED provides information about

the switching state of the relay contact
• LED on = relay is energized
• LED off = relay has dropped
The flashing is independent of the position of the dip switch S1.

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 Dip switch
S1 The position of switch S1 determines, whether the relay is attracted up or released at
material flow.
Position ”1” (up) causes alarm in case of material flow:
• Material flow: - relay is energized
- contacts 4 + 5 closed
• No material flow: - relay is released
- contacts 3 + 4 closed
Position ”2” (down) causes alarm when there is no material flow:
• Material flow: - relay is released
- contacts 3 + 4 closed
• No material flow: - relay is energized
- contacts 4 + 5 closed

S2 The sensitivity can be adjusted with the dip switch S2.

Position 2 (down): Sensor is set to insensitive
Position 1 (up): Sensor is set to sensitive

Potentiometer
P1 Adjustment of the threshold based on the sensitivity
Left stop = lowest sensitivity
Right stop = highest sensitivity

P2 Setting for time delay on the relay contact

Left stop = 0.25 s
Right stop =5s

6. Commissioning
The potentiometer P1 is used to set the threshold to which the relay should switch. The measurement signal
is adjusted so that a clear distinction between material flow and no material flow can be made.
Procedure:
Put the process into operation so that a material flow is guaranteed. LED 1 must now light up depending on
the material flow. If it does not light up, switch S2 must be set to position “1” (up). If the LED 1 still does not
light up, the installation situation should be checked. Alternatively, a highly sensitive sensor can be obtained
via ENVEA Process. If the material is detected, DIP switch S1 can be used to select whether the relay should
be energized (position “1”) or released (position “2”) when material flows.
The threshold of the alarm relay is set via the potentiometer P1. P1 must be turned to the right at least until
LED 2 lights up and the relay is energized.
If the material flow is interrupted, LED 1 should switch off and the relay and LED 2 should switch off at the
latest after the set delay time has expired.
The delay time is set with the potentiometer P2 to the application requirements in the range of 0.25 - 15 s.

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6.1 Default settings
The control elements are set in the following positions when delivered:
• Potentiometer P1 (fine adjustment of sensitivity): left stop = insensitive
• Switch S2 (coarse adjustment of sensitivity): switch to position „2“ (below) = insensitive
• Potentiometer P2 (delay time): left stop = minimum delay of 0.25 s

7. Fault clearance

Error Cause Action

Incorrect sensor parameter Check installation situation;

Relay doesn‘t switch at
material flow
set measuring point to
maximum sensitivity:
Too big distance between
- P1 right stop
sensor and material
- P2 left stop
- S2 position „1“ (up)
Incorrect sensor position
Repeat commissioning

Incorrect sensor parameter Check installation situation;

shield foreign movements;
Detection of vibrations or other Set measuring point to
LED 1 lights up without
moving parts within process maximum insensitivity:
material flow
- P1 left stop
- S2 position „2“ (down)
Repeat commissioning

Incorrect cabling Check cable connection and

LED 1 is flashing continuously power supply
Sensor defect Contact ENVEA Process

8. Notice
• Avoidance of reflection by vibration or moving line parts.
• Avoid strong vibrations.
• Various process adapters are available to protect the sensor, observe ATEX zones or solve difficult
process conditions .
• Setting of the sensitivity by potentiometer P1 up to the switching threshold (LED 2 lightening).

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9. Technical data
Housing Stainless steel 1.4571
Protective system IP65
Process temperature -20…+80 °C
-20…+220 °C (with processadapter)
Max. 1000 °C (with ceramicflange)
Ambient temperature - 20 ... + 60 °C
Dimensions Housing: L 216 mm / Ø 52 mm / Thread: L 30 mm / G 1½“
Cable fitting M16 (Ø 5-10 mm)
Max. working pressure 1 bar
Detection range 0 ... 2 m (dependent on application)
Min. required material speed 0.1 m/s
for detection
Power supply 24 V DC / AC ± 10 %
Power consumption approx. 1.7 VA
Current consumption 70 mA at 24 V
Relay contact Max. switching capacity: 250 V AC
Max. start-up current: 6A
Max. breaking capacity 230 V AC: 250 VA
Max. switching current DC1: 3/110/220 V: 3/0.35/0.2 A
Min. breaking capacity: 500 mW (10 V/5 mA)
Fall-delay time 250 ms …15 s (continuously adjustable)
Measuring frequency K-Band 24.125 GHz / ± 100 MHz
Transmitting power max. 5 mW
Approvals FTZ and PTT
Weight 1.0 kg G 1 1/2"
ø 52

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ENVEA Process GmbH

(All rights reserved.)

Gutedelstraße 31 · 79418 Schliengen (Germany)

Fon +49 7635 827248-0 · Fax +49 7635 827248-48 · www.envea.global

PART OF THE ENVEA GROUP

EN 04/08/2020 10